Package on package structure and method for forming the same

ABSTRACT

Some embodiments relate to a semiconductor device package, which includes a substrate with a contact pad. A non-solder ball is coupled to the contact pad at a contact pad interface surface. A layer of solder is disposed over an outer surface of the non-solder ball, and has an inner surface and an outer surface which are generally concentric with the outer surface of the non-solder ball. An intermediate layer separates the non-solder ball and the layer of solder. The intermediate layer is distinct in composition from both the non-solder ball and the layer of solder. Sidewalls of the layer of solder are curved or sphere-like and terminate at a planar surface, which is disposed at a maximum height of the layer of solder as measured from the contact pad interface surface.

REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation of U.S. application Ser. No.14/975,911 filed on Dec. 21, 2015, which is a Divisional of U.S.application Ser. No. 13/526,073 filed on Jun. 18, 2012 (now U.S. Pat.No. 9,219,030 issued on Dec. 22, 2015), which claims priority to U.S.Provisional Application No. 61/624,928 filed on Apr. 16, 2012. Thecontents of the above-referenced matters are hereby incorporated byreference in their entirety.

This application relates to the following co-pending and commonlyassigned patent application Ser. No. 13/406,031 (Attorney Docket No.TSMC2011-1346), entitled “Mechanisms of Forming Connectors for Packageon Package” and filed on Feb. 27, 2012, which is incorporated herein inits entirety.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as personal computers, cell phones, digital cameras, and otherelectronic equipment, as examples. Semiconductor devices are typicallyfabricated by sequentially depositing insulating or dielectric layers,conductive layers, and semiconductive layers of materials over asemiconductor substrate, and patterning the various material layersusing lithography to form circuit components and elements thereon.

The semiconductor industry continues to improve the integration densityof various electronic components (e.g., transistors, diodes, resistors,capacitors, etc.) by continual reductions in minimum feature size, whichallow more components to be integrated into a given area. These smallerelectronic components also require smaller packages that utilize lessarea and/or lower height than packages of the past, in someapplications.

Thus, new packaging technologies, such as package on package (PoP), havebegun to be developed, in which a top package with a device die isbonded to a bottom package with another device die. By adopting the newpackaging technologies, the integration levels of the packages may beincreased. These relatively new types of packaging technologies forsemiconductors face manufacturing challenges.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1A shows a perspective view of a package, in accordance with someembodiments.

FIG. 1B shows a cross-sectional view of a portion of package of FIG. 1Acut along line P-P, in accordance with some embodiments.

FIGS. 2A-2G are cross-sectional views of a package on package structureat various manufacturing stages, in accordance with some embodiments.

FIGS. 3A-3C are cross-sectional views of bonded metal ball structures,in accordance with some embodiments.

FIG. 4 is a cross-sectional view of a bonded metal ball structure afterthe top surface of a metal ball is flattened, in accordance with someembodiments.

FIG. 5 is a cross-sectional view of a semiconductor die bonded to asubstrate filled with an underfill in the space between thesemiconductor die and the substrate, in accordance with someembodiments.

FIGS. 6A-6D are cross-sectional views of a package on package structureat various manufacturing stages, in accordance with some embodiments.

Corresponding numerals and symbols in the different figures generallyrefer to corresponding parts unless otherwise indicated. The figures aredrawn to clearly illustrate the relevant aspects of the embodiments andare not necessarily drawn to scale.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of the embodiments of the present disclosure arediscussed in detail below. It should be appreciated, however, that thepresent disclosure provides many applicable inventive concepts that canbe embodied in a wide variety of specific contexts. The specificembodiments discussed are merely illustrative of specific ways to makeand use the disclosure, and do not limit the scope of the disclosure.

FIG. 1A shows a perspective view of a package assembly 100 having apackage 110 bonded to another package 120, which is further bonded to asubstrate 130 in accordance with some embodiments. Each package, such aspackage 110 or package 120, includes at least a semiconductor die (notshown). The semiconductor die includes a substrate as employed in asemiconductor integrated circuit fabrication, and integrated circuitsmay be formed therein and/or thereupon. The semiconductor substrate isdefined to mean any construction comprising semiconductor materials,including, but not limited to, bulk silicon, a semiconductor wafer, asilicon-on-insulator (SOI) substrate, or a silicon germanium substrate.Other semiconductor materials including group III, group IV, and group Velements may also be used. The substrate 130 may further comprise aplurality of isolation features (not shown), such as shallow trenchisolation (STI) features or local oxidation of silicon (LOCOS) features.The isolation features may define and isolate the variousmicroelectronic elements. Examples of the various microelectronicelements that may be formed in the substrate 130 include transistors(e.g., metal oxide semiconductor field effect transistors (MOSFET),complementary metal oxide semiconductor (CMOS) transistors, bipolarjunction transistors (BJT), high voltage transistors, high frequencytransistors, p-channel and/or n-channel field effect transistors(PFETs/NFETs), etc.); resistors; diodes; capacitors; inductors; fuses;and other suitable elements. Various processes are performed to form thevarious microelectronic elements including deposition, etching,implantation, photolithography, annealing, and other suitable processes.The microelectronic elements are interconnected to form the integratedcircuit device, such as a logic device, memory device (e.g., SRAM), RFdevice, input/output (I/O) device, system-on-chip (SoC) device,combinations thereof, and other suitable types of devices.

Substrate 130 may be made of a semiconductor wafer, or a portion ofwafer. In some embodiments, substrate 130 includes silicon, galliumarsenide, silicon on insulator (“SOI”) or other similar materials. Insome embodiments, substrate 130 also includes passive devices such asresistors, capacitors, inductors and the like, or active devices such astransistors. In some embodiments, substrate 130 includes additionalintegrated circuits. Substrates 130 may further include throughsubstrate vias (TSVs) and may be an interposer. In addition, thesubstrate 130 may be made of other materials. For example, in someembodiments, substrate 130 is a multiple-layer circuit board. In someembodiments, substrate 130 also includes bismaleimide triazine (BT)resin, FR-4 (a composite material composed of woven fiberglass clothwith an epoxy resin binder that is flame resistant), ceramic, glass,plastic, tape, film, or other supporting materials that may carry theconductive pads or lands needed to receive conductive terminals.

Package 110 is bonded to package 120 via connectors 115, and package 120is bonded to substrate 130 via connectors 125. FIG. 1B is across-sectional view of a portion of the PoP package of FIG. 1A cutalong line P-P, in accordance with some embodiments. FIG. 1B showsconnectors 115 and 125 near the edge of chip package assembly 100. Thereare connectors 125 near the center of package 120, in some embodiments.A portion of connectors 115 is formed in openings 116 of package 120.Openings 116 are formed by etching the molding material of package 120.As a result, connectors 115 may also be called through molding vias(TMVs). In some embodiments, the openings 116 are formed by laserdrills, and the width W₁ of openings 116 is quite large. For example,the width W₁ is in a range from about 300 μm to about 600 μm, inaccordance with some embodiments. In some embodiments, pitch P₁ betweentwo adjacent connectors 115 is in a range from about 400 μm to about 800μm. The relatively large pitch limits design flexibility and complexitythat are needed for advanced devices. In addition, laser drill ofopenings 116 leaves the isolation regions 117 between connectors 115relatively thin in the top portions 117′, which increase the risk ofshorting between connectors 115. Therefore, there is a need of findingalternative mechanisms for forming connectors 115 between package 110and package 120.

FIGS. 2A-2G are cross-sectional views of a package on package structureat various manufacturing stages, in accordance with some embodiments.FIG. 2A shows a substrate 200 with contact pads 210 for making externalconnections, in accordance with some embodiments. Substrate 200 may bemade of a semiconductor wafer, or a portion of a wafer. In someembodiments, substrate 200 includes silicon, gallium arsenide, siliconon insulator (“SOI”) or other similar materials. In some embodiments,substrate 200 also includes passive devices such as resistors,capacitors, inductors and the like, or active devices such astransistors. In some embodiments, substrate 200 includes additionalintegrated circuits. Substrates 200 may further include throughsubstrate vias (TSVs) and may be an interposer. In addition, thesubstrate 200 may be made of other materials. For example, in someembodiments, substrate 200 is a multiple-layer circuit board. In someembodiments, substrate 200 also includes bismaleimide triazine (BT)resin, FR-4, FR-5, which is similar to FR-4, ceramic, glass, plastic,tape, film, or other supporting materials that may carry the conductivepads or lands needed to receive conductive terminals. Contact pads 210are made of conductive material(s) and are connected to interconnect(not shown) in substrate 200.

Metal balls 240 are then mounted on contact pads 210 and bond withcontact pads 210 to form mounted metal ball structure 255, as shown inFIG. 2B in accordance with some embodiments. The mounting process mayinvolve placing the metal balls 240 on the contact pads 210 andperforming a reflow process to bond the contact metal balls 240 tocontact pads 210. FIG. 3A is a cross-sectional view of an enlargedregion 250 of FIG. 2B, in accordance with some embodiments. FIG. 3Ashows region 250 includes substrate 200 and mounted metal ball structure255, in accordance with some embodiments. Substrate 200 includesinterconnect structures 205, which connect to conductive pads 208 andconductive pads 207 on opposite sides of substrate 200, as shown in FIG.3A in accordance with some embodiments.

In some embodiments, interconnect structures 205 includes the metallines and vias formed of copper or copper alloys. In some embodiments,interconnect structures 205 are surrounded and insulated by inter-layerdielectrics (ILDs) and/or inter-metal dielectrics (IMDs), which may bemade of undoped silicon glass, doped film, low dielectric constant(low-k) dielectric, or combinations thereof. Conductive pads 208 arepart of the mounted ball structures 210, in accordance with someembodiments. In some embodiments, conductive pads 208 and 207 comprisealuminum, copper, silver, gold, nickel, tungsten, alloys thereof, and/ormulti-layers thereof.

A portion of each of the conductive pads 208 is protected by apassivation layer 230 with the remaining portion of each of theconductive pads 208 exposed. Similarly, conductive pads 207 are alsopartially protected by a passivation layer 231. Passivation layer 230and 231 are made of soft (or deformable) dielectric material(s), such aspolymers, to relieve bonding stress, in accordance with someembodiments. In some embodiments, additional passivation layer(s) isformed over interconnect structures 205 and at the same level of, orover, conductive pad 208. In some embodiments, the additionalpassivation layer(s) includes silicon oxide, silicon nitride, un-dopedsilicate glass (USG), polyimide, or combinations thereof.

An optional bonding layer 245 is formed over the conductive pads 208, inaccordance with some embodiments. The optional bonding layer 245 couldhelp bonding metal balls 240 to conductive pads 208. The metal balls 240are made of non-solder materials, such as copper, aluminum, silver,gold, nickel, tungsten, alloys thereof, and/or multi-layers thereof, inaccordance with some embodiments. Metal balls 240 are made of one ormore non-solder materials so that they do not deform and short withneighboring metal balls 240 under a thermal process. In someembodiments, the (maximum) width W₂ of the metal balls 240 is in a rangefrom about 100 μm to about 200 μm. In some embodiments, the pitch P₂ ofmetal balls 240 is in a range from about 150 μm to about 300 μm.

As mentioned above, the bonding layer 245 could be used to improvebonding between conductive pads 208 and metal balls 240. For example, ifboth the conductive pads 208 and metal balls 240 are made of copper, thebonding layer 245 may be made of solder, which can be used to bondcopper to copper. In some embodiments, the bonding layer 245 is made ofsolder or solder alloy such as Sn—Ag, Sn—Ag—Cu, Sn—Bi, Sn—Cu, etc. Insome embodiments, bonding layer 245 is made of solder alloy includingSn, Pb, Ag, Cu, Ni, bismuth (Bi), or combinations thereof.

In some embodiments, the (optional) bonding layer 245 includes twosub-layers. For example, the two sub-layers may include asolder-containing layer over a protective layer, such as a layer of Tiand/or Ni. The protective layer is placed between the solder-containinglayer and conductive pads 208. The protective layer could prevent theoxidation of copper-containing metal balls 240 and improves the wettingof metal balls 240. In some embodiments, the thickness of the bondinglayer 245 is in a range from about 0.5 μm to about 10 μm.

After metal balls 240 are placed on the bonding layer 245, a reflowprocess is performed to bond the metal balls 240 to the conductive pads208 with the help of the bonding layer 245. For example, if the metalballs 240 and the conductive pads 208 are made of copper or copperalloy, a bonding layer 245 made of solder would help bond the coppercontaining metal balls 240 and conductive pads 208 together. In someembodiments, the reflow temperature is in a range from about 180° C. toabout 240° C. After the reflow process, the metal balls 240 are bondedto (or mounted on) the conductive pads 208 to form mounted metal ballstructure 255. In at least one embodiment, conductive pads 208, bondinglayer 245 and metal balls 240 form the mounted metal ball structures255, in accordance with some embodiments. If the metal balls 240 includecopper and the bonding layer 245 includes solder, an inter-metalcompound (IMC) layer 242 may be formed between the metal balls 240 andthe bonding layer 245. As mentioned above, a solder-containing bondinglayer 245 could include a stable film over the solder to prevent theformation of the IMC layer 242.

The conductive pads 207 may be covered by a bonding layer 247 inaccordance with some embodiments. Each of the conductive pads 207 andaccompanying bonding layer 247 form a connecting structure 220, which isused to bond with an external connector (not shown), in accordance withsome embodiments. In some embodiments, the bonding layer 247 is notneeded. For example, if the external connectors (not shown) are made ofsolder and the conductive pads 207 are made of copper, the bonding layer247 is not needed for bonding. In some embodiments, the bonding layer247 is made of the same material as bonding layer 245. In someembodiments, the bonding layer 247 is made of a material different fromthat of bonding layer 245. The existence and choice of the material(s)for bonding layer 247 depend on the material of conductive pads 207 andthe external connectors (not shown) to be bonded to the conductive pads207.

FIG. 3B shows mounted metal ball structure 255′, in accordance with someother embodiments. The metal balls 240′ bonded to a conductive pad 208includes an inner metal ball 240 _(I) and one or more coating layers,such as coating layer 240 _(C1) and optional intermediate layer 240_(C2), in accordance with some embodiments. The inner metal balls 240_(I) are similar to metal balls 240 and may be made of various materialsdescribed above. In some embodiments, the width W₃ of the inner metalballs 240 _(I) is in a range from about 100 μm to about 250 μm. Thecoating layer(s) is used to improve bonding between the metal balls 240′and conductive pads 208. In some embodiments, the coating layer(s)replaces the bonding layer 245 described in FIG. 3A, in accordance withsome embodiments. For example, if the inner metal balls 240 _(I) aremade of copper or copper alloy and conductive pads 208 are made ofcopper, a solder-containing coating layer 240 _(C1) would help bond theinner metal balls 240 _(I) to conductive pads 208. In some embodiments,the manufacturing of coating the inner metal balls 240 _(I) would besimpler than forming a bonding layer 245, which involves deposition ofthe bonding layer 245 and removing of excess bonding layer 245 away fromconductive pads 208. Removing the excess bonding layer 245 could involvepatterning of the bonding layer and an etching process to remove excessbonding layer 245. In some embodiments, the coating layer 240 _(C1) ismade of materials similar to materials for bonding layer 245. In someembodiments, the thickness of coating layer 240 _(C1) is in a range fromabout 0.5 μm to about 10 μm. Even with the coating layer, metal balls240′ would deform much less under reflow than solder balls. As a result,metal balls 240′ are less likely to short to each other after reflow.The ranges of width and pitch of metal balls 240′ are similar to thoseof metal balls 240.

In some embodiments, an intermediate layer 240 _(C2) is formed betweenthe inner metal balls 240 _(I) and coating layer 240 _(C1). Theintermediate layer 240 _(C2) is conductive and prevents the formation ofinter-metal compound (IMC) between the inner metal balls 240 _(I) andcoating layer 240 _(C1) during and after the reflow process for bondingthe metal balls 240′ with the conductive pads 208 in accordance withsome embodiments. For example, if the inner metal balls 240 _(I) includecopper and the coating layer 240 _(C1) includes solder, an intermediatelayer 240 _(C2) made of a metal or alloy inert to copper and solderunder reflow condition would prevent forming IMC between the inner metalballs 240 _(I) and the coating layer 240 _(C1). In some embodiments, theintermediate layer 240 _(C2) includes Ti and/or Ni. In some embodiments,the thickness of intermediate layer 240 _(C2) is in a range from about0.5 μm to about 10 μm.

In some embodiments, a temporary protective layer 246′ is formed overconductive pads 208 as shown in FIG. 3B. The temporary protective layer246′ may prevent the oxidation of the conductive pads 208 duringtransport. For example, the temporary protective layer 246′ is made ofan organic material, which would evaporate under reflow temperature toallow the metal balls 240′ to come in contact with conductive pads 208.In some embodiments, the protective layer 246 is made of an organicsolderability preservative (OSP), which is a polymer. For example, theOSP maybe organic azole based.

In some embodiments, a protective layer 246 is formed over conductivepads 208 as shown in FIG. 3C. The protective layer 246 may prevent theoxidation of the conductive pads 208 during transport. For example, ifthe conductive pads 208 include copper, the proactive layer 246 may bemade of a stable metal, such as Ti, Ni, Au, Ag, a combination thereof,or alloy thereof. In some embodiments, the thickness of the temporaryprotective layer 246′ or the protective layer 246 is in a range fromabout 0.5 μm to about 10 μm.

In some embodiments, the top surface of the metal balls 240 or 240′ isflattened to improve the contact between the connectors (not shown) tobe bonded to metal balls 240 or 240′. FIG. 4 shows a bonded metal ballstructure after a top surface of metal ball 240 is flattened, inaccordance with some embodiments. The flattened surface 248 issubstantially parallel to surface 201 of substrate 200, in accordancewith some embodiments. Weight can be applied over a plate placed overmetal balls 240 to flatten the top surface. In some embodiment the widthW₄ of the flat portion is in a range from about 20 μm to about 100 μm.In some embodiments, the ratio of width W₄ to the width W₂ of the metalballs 240 is in a range from about 20% to about 80%. However, theflattening process optional. It might not be needed in some embodiments.

After metal balls 240 or 240′ are bonded (or mounted) and optionallyflattened on the conductive pads 208, semiconductor dies 105 are placedon substrate 200 as shown in FIG. 2C in accordance with someembodiments. Each semiconductor die 105 is placed between metal balls240. To simplify description, only metal balls 240 are used from hereon.However, the following description is applicable to metal balls 240′described above as well. In some embodiments, a reflow process isperformed to bond the connectors (not shown) on semiconductor dies 105to contact pads (not shown) on substrate 200 to form bonding structures153.

Each semiconductor die 105 includes a substrate as employed in asemiconductor integrated circuit fabrication, and integrated circuitsmay be formed therein and/or thereupon. The semiconductor substrate isdefined to mean any construction comprising semiconductor materials,including, but not limited to, bulk silicon, a semiconductor wafer, asilicon-on-insulator (SOI) substrate, or a silicon germanium substrate.Other semiconductor materials including group III, group IV, and group Velements may also be used.

Examples of the various microelectronic elements that may be formed inthe semiconductor dies 105 include transistors (e.g., metal oxidesemiconductor field effect transistors (MOSFET), complementary metaloxide semiconductor (CMOS) transistors, bipolar junction transistors(BJT), high voltage transistors, high frequency transistors, p-channeland/or n-channel field effect transistors (PFETs/NFETs), etc.);resistors; diodes; capacitors; inductors; fuses; and other suitableelements. Various processes are performed to form the variousmicroelectronic elements including deposition, etching, implantation,photolithography, annealing, and other suitable processes. Themicroelectronic elements are interconnected to form the integratedcircuit device, such as a logic device, memory device (e.g., SRAM), RFdevice, input/output (I/O) device, system-on-chip (SoC) device,combinations thereof, and other suitable types of devices.

In some embodiments, an underfill 154 fills the space betweensemiconductor dies 105 and substrate 200 as shown in FIG. 5. Underfill154 provides support for semiconductor dies 105 and prevents cracking ofsolder joints (not shown) on bonding structures 153 electricallyconnecting the semiconductor dies 105 and conductive elements(interconnect) in substrate 200. However, forming underfill 154 aftersemiconductor dies 105 being bonded to substrate 200 is optional. Insome embodiments, underfill 154 is not formed. Underfill 154 may be madeof thermosetting polymers, in accordance with some embodiments. Forexample, Underfill 154 may be made of (or include) epoxy resin (aminetype, phenol type, anhydrates types, etc.), silicon fillers, curingagents, addictives and/or hardener.

Afterwards, packages 110 are placed above substrate 200 and are mountedon metal balls 240, as shown in FIG. 2D in accordance with someembodiments. Each package 110 includes two semiconductor dies 112 and113, with die 113 disposed over die 112, in accordance with someembodiments. However, package 110 could include one semiconductor die ormore than two semiconductor dies. In some embodiments, there is a gluelayer (not shown) between dies 112 and 113. Semiconductor dies 112 and113 may include various microelectronic elements, as described above forsemiconductor dies 105. The examples of these various microelectronicelements have been described above. Semiconductor die 112 is bonded to asubstrate 115. Substrate 115 may include various materials and/orcomponents described above for the substrate of semiconductor die 105.Semiconductor die 112 is electrically connected to conductive elements(not shown) in substrate 115 via bonding wires 114, in accordance withsome embodiments. Similarly, semiconductor die 113 is electricallyconnected to the conductive elements in substrate 115 via bonding wires116. Package 110 also includes a molding compound 111, which coverssemiconductor dies 112 and 113, and also bonding wires 114 and 116.

Each package 110 includes a number of connectors 117 surroundingsemiconductor die 105, in accordance with some embodiments. Connectors117 are made of a conductive material, such as solder, solder alloy,etc. Connectors 117 are formed on conductive structures (not shown) onthe surface of substrate 115 to electrically connect to elements insubstrate 115. After package 110 is placed over substrate 200 withconnectors 117 of package 110 in contact with metal balls 240, a reflowprocess is performed to bond the connectors 117 to metal balls 240, inaccordance with some embodiments. After the connectors 117 are bonded tometal balls 240 to form bonding structures 118, packages 110 areconsidered “mounted” on substrate 200. Due to the non-solder metal balls240, the height of the bonding structures 118 can be controlled moreconsistently. In some embodiments, the height H₁ between a top surface201 of substrate 200 and the bottom surface 101 of package 110 (orsubstrate 115) is in a range from 100 μm to about 250 μm.

After packages 110 are mounted on substrate 200, a molded underfill(MUF) 260 is applied on substrate 200 to fill the space between packages110 and between packages 110 and substrate 200, as shown in FIG. 2E inaccordance with some embodiments. In some embodiments, the MUF 260 hasfillers. The MUF 260 supports packages 110 and prevents cracking ofsolder joints on bonding structures 118 and between metal balls 240 andconductive pads 208. Further, MUF 260 could also prevent the bending(deformation) of package on package structures on substrate 200 due tomismatch of coefficients of thermal expansion (CTE) of materials onsubstrate 200 after thermal cycling. In some embodiments, MUF 260 ismade of epoxy resin (amine type, phenol type, anhydrates types, etc.),silicon fillers, curing agents, additives and/or hardener materials. Ifthere is no underfill 154 underneath semiconductor dies 105, MUF 260also fills the space between semiconductor dies 105 and substrate 200 toprotect bonding structures 153. Processing cost could be saved by using260 to fill the space packages 110 and substrate 200 and simultaneouslyfilling the space between semiconductor dies 105 and substrate 200.

After the MUF forming process, connectors 270 are bonded to conductivepads 207 (not shown) on the other side (opposite from packages 110) ofsubstrate 200, as shown in FIG. 2F in accordance with some embodiments.Connectors 270 are made of conductive materials. They could be solder,solder alloy, copper, copper alloy, gold, or gold alloy, etc. Asmentioned above, there could be a bonding layer 247 covering conductivepads 207. The connectors 270 are bonded to the conductive pads 207 by areflow process.

After connectors 270 are bonded to the opposite side of substrate 200from packages 110, substrate 200 with bonded multiple packages 110 andsemiconductor die 105 is singulated (or sawed) into individual packages,each of which has a package 110 and a semiconductor die 105. FIG. 2Gshows substrate 200 after it is singulated into individual package 290,in accordance with some embodiments. Each individual package 290 is apackage on package structure and has a package 110 and a semiconductordie 105, in accordance with some embodiments.

The embodiments described above in FIGS. 2A-2G and 3-5 of formingpackage 290 of package on package (PoP) structure involves MUF 260. Insome alternative embodiments, an exposed die molding underfill (eMUF)260′ is formed on substrate with the top portions of semiconductor die105 and metal balls 240 exposed, as shown in FIG. 6A in accordance withsome embodiments. After semiconductor dies 105 are placed on and bondedto substrate 200 as shown in FIG. 2C described above, eMUF 260′ isformed over substrate 200. By forming the exposed eMUF 260′, there is anair gap 285 between each package 110 and semiconductor die 105. The airgap 285 allows chips, such as chips 112 and 113, on package 110 to besubstantially thermally isolated from semiconductor die 105. As aresult, heat generated from chips 112 and 113, which are in proximity ofsemiconductor die 105, is less likely to be transferred to semiconductordie 105, and vice versa. The eMUF 260′ still can protect the solderjoints between metal balls 240 and conductive pads 208. The eMUF 260′also can help reducing the bending of substrate 200 before singulationand formed packages after singulation due to mismatch of CTEs.

After the eMUF 260′ is formed on substrate 200 as described above,packages 110 are bonded to substrate 200, as shown in FIG. 6B inaccordance with some embodiments. The bonding of packages 110 tosubstrate 200 has been described above. Connectors 270 are then attachedto substrate 200 in a similar manner described above in FIG. 2F, inaccordance with some embodiment. FIG. 6C shows connectors 270 bonded tosubstrate 200, in accordance with some embodiments. Substrate 200 withpackages 110 and semiconductor dies 105 is then singulated intoindividual packages 290′, as shown in FIG. 6D in accordance with someembodiments. FIGS. 2A-2C and 6A-4D show cross-sectional views ofpackaging structures in sequential process flow of forming a package onpackage structure, in accordance with some embodiments.

The described embodiments of mechanisms of forming a package on package(PoP) structure involve bonding with connectors with non-solder metalballs to a packaging substrate. The non-solder metal balls may include asolder coating layer. The connectors with non-solder metal balls canmaintain substantially the shape of the connectors and control theheight of the bonding structures between upper and lower packages. Theconnectors with non-solder metal balls are also less likely to result inbridging between connectors or disconnection (or cold joint) of bondedconnectors. As a result, the pitch of the connectors with non-soldermetal balls can be kept small.

In some embodiments, a semiconductor device package includes a substratewith a contact pad. A semiconductor die is bonded to the contact pad bya first bonding structure. The first bonding structure includes a metalball comprising a non-solder material, a solder layer over a surface ofthe non-solder material, and an intermediate layer between the solderlayer and the non-solder material. The intermediate layer is configuredto prevent formation of an intermetallic compound between the metal balland the solder layer. The non-solder material includes copper, aluminum,silver, gold, nickel, tungsten, alloys thereof, or combinations thereof,and the intermediate layer comprises titanium.

In some other embodiments, an apparatus includes a substrate and apackage that includes a first semiconductor die surrounded by a moldingcompound. The first semiconductor die of the package is bonded to thesubstrate by a first conductive bonding structure. The first conductivebonding structure includes a metal ball made of non-solder material, alayer of solder over a surface of the metal ball, and an intermediatelayer between the metal ball and the layer of solder. The intermediatelayer is distinct from both the metal ball and the layer of solder andis configured to prevent formation of an intermetallic compound betweenthe metal ball and the layer of solder.

Still some other embodiments relate to a solder ball for couplingcircuit components. The solder ball includes a metal ball made ofnon-solder material, a layer of solder over a surface of the metal ball,and an intermediate layer between the metal ball and the layer ofsolder. The intermediate layer is distinct in composition from both themetal ball and the layer of solder.

Although embodiments of the present disclosure and their advantages havebeen described in detail, it should be understood that various changes,substitutions and alterations can be made herein without departing fromthe spirit and scope of the disclosure as defined by the appendedclaims. For example, it will be readily understood by those skilled inthe art that many of the features, functions, processes, and materialsdescribed herein may be varied while remaining within the scope of thepresent disclosure. Moreover, the scope of the present application isnot intended to be limited to the particular embodiments of the process,machine, manufacture, composition of matter, means, methods and stepsdescribed in the specification. As one of ordinary skill in the art willreadily appreciate from the disclosure of the present disclosure,processes, machines, manufacture, compositions of matter, means,methods, or steps, presently existing or later to be developed, thatperform substantially the same function or achieve substantially thesame result as the corresponding embodiments described herein may beutilized according to the present disclosure. Accordingly, the appendedclaims are intended to include within their scope such processes,machines, manufacture, compositions of matter, means, methods, or steps.

What is claimed is:
 1. A semiconductor device package, comprising: asubstrate with a contact pad; a non-solder ball coupled to the contactpad at a contact pad interface surface; a layer of solder over an outersurface of the non-solder ball, the layer of solder having an innersurface and an outer surface which are generally concentric with theouter surface of the non-solder ball; and an intermediate layerseparating the non-solder ball and the layer of solder, wherein theintermediate layer is distinct in composition from the non-solder balland the layer of solder; and wherein sidewalls of the layer of solderare curved or sphere-like and terminate at a planar surfacecorresponding to a maximum height for the layer of solder, the maximumheight being measured from the contact pad interface surface.
 2. Thesemiconductor device package of claim 1, wherein the non-solder ballincludes copper, aluminum, silver, gold, nickel, tungsten, alloysthereof, or combinations thereof, and the intermediate layer comprisestitanium.
 3. The semiconductor device package of claim 1, wherein thesemiconductor device package has another non-solder ball next to thenon-solder ball, and a pitch of the non-solder ball and the anothernon-solder ball is in a range from about 150 μm to about 300 μm.
 4. Thesemiconductor device package of claim 1, wherein the layer of solder isa continuous layer that coats the intermediate layer.
 5. Thesemiconductor device package of claim 1, wherein the non-solder ball isarranged over and electrically coupled to the contact pad, and whereinthe intermediate layer has a first annular thickness on a first portionof the non-solder ball between the non-solder ball and the contact padand has a second annular thickness on a second portion of the non-solderball, the second annular thickness being greater than the first annularthickness.
 6. The semiconductor device package of claim 1, wherein thelayer of solder has a thickness in a range from 0.5 μm to about 10 μm.7. The semiconductor device package of claim 1, wherein the intermediatelayer has a thickness ranging from about 0.5 μm to about 10 μm.
 8. Thesemiconductor device package of claim 1, wherein the intermediate layeris a continuous layer that coats an outer surface of the non-solderball.
 9. A semiconductor device package, comprising: a substrate with acontact pad; a non-solder ball coupled to the contact pad at a contactpad interface surface; a layer of solder over an outer surface of thenon-solder ball, the layer of solder having an inner surface and anouter surface which are generally concentric with the outer surface ofthe non-solder ball; and an intermediate layer separating the non-solderball and the layer of solder, wherein the intermediate layer is distinctin composition from the non-solder ball and the layer of solder; andwherein the intermediate layer is elongated along an axis that isperpendicular to the contact pad interface surface, such that theintermediate layer has a height as measured from the contact padinterface surface to an uppermost extent of the intermediate layer alongthe axis, and has a diametric width between its outermost sidewalls, thediametric width being less than the height.
 10. The semiconductor devicepackage of claim 9, wherein the intermediate layer is distinct from boththe non-solder ball and the layer of solder and is configured to preventformation of an intermetallic compound between the non-solder ball andthe layer of solder.
 11. The semiconductor device package of claim 9,further comprising: a molded underfill on the substrate.
 12. Thesemiconductor device package of claim 9, wherein the intermediate layercomprises titanium, and wherein material of the non-solder ball includescopper, aluminum, silver, gold, nickel, tungsten, alloys thereof, orcombinations thereof.
 13. The semiconductor device package of claim 9,wherein the layer of solder and the intermediate layer are generallyconcentric, and the non-solder ball is arranged over and electricallycoupled to the contact pad, wherein the intermediate layer has a firstannular thickness on a first portion of the non-solder ball between thenon-solder ball and the contact pad and has a second annular thicknesson a second portion of the non-solder ball, the second annular thicknessbeing greater than the first annular thickness.
 14. A semiconductordevice package, comprising: a substrate with a contact pad; a metal ballbonded to the contact pad to form a first bonding structure, wherein themetal ball comprises a non-solder material, wherein the bonded metalball includes a solder layer over a surface of the non-solder materialand an intermediate layer between the solder layer and the non-soldermaterial, and the intermediate layer is configured to prevent formationof an intermetallic compound; a semiconductor die bonded to thesubstrate, wherein the semiconductor die is disposed next to the firstbonding structure; a die package, having a connector, bonded to asurface of the substrate bonded with the semiconductor die, wherein asecond bonding structure is formed between the connector on the diepackage and the metal ball bonded to the substrate; and a moldedunderfill on the substrate.
 15. The semiconductor device package ofclaim 14, wherein the solder layer and the intermediate layer aregenerally concentric with one another, and the metal ball is arrangedover and electrically coupled to the contact pad, wherein theintermediate layer has a first annular thickness on a first portion ofthe metal ball between the metal ball and the contact pad and has asecond annular thickness on a second portion of the metal ball, thesecond annular thickness being greater than the first annular thickness.16. The semiconductor device package of claim 14, wherein theintermediate layer is a continuous layer that coats an outer surface ofthe metal ball and has different annular thicknesses at differentlocations along the outer surface of metal ball.
 17. The semiconductordevice package of claim 16 wherein the solder layer is a continuouslayer that coats an outer surface of the intermediate layer.
 18. Thesemiconductor device package of claim 14, wherein a width or diameter ofthe metal ball is in a range from about 100 μm to about 200 μm.
 19. Thesemiconductor device package of claim 14, wherein the solder layer has athickness in a range from 0.5 μm to about 10 μm.
 20. The semiconductordevice package of claim 14, wherein the intermediate layer has athickness ranging from about 0.5 μm to about 10 μm.